Building material



Mal'Ch 15, 1932. J, H, DELANEY BUILDING MATERIAL 2 Sheets-Sheet l Original Filed July lO. 1929 2 4Sheets-Sheet 2 March 15, 1932. J. H. DELANEY BUILDING MATERIAL original Filed July lo, 1929 Il ....v

A 'fforhey Patented Mar. 15, 1932 UNITED STATES PATENT :orales JOHN HC. DELANEY, 0F LOS ANGELIS, CALIFORNIA; UNION' im l TRUST C0. 0F A:|305 ANGELES ADMINISTRATOR -OF JOHN `H. Dm, DEGEA'SED BUILDING riginal 'application led luly l0, '1929,Seria`1 lo. 877,207. Mld and thilflpplicltim il Illy 13, 1980. Serial lo. 51;974.

'This invention relates to building mate- I rial, and especially to 'folda'ble boards that can be utilized to' form cellular vcompartments, or hollow blocks, for walls, ceilings, floors or the like.

It is one of the objects of my invention 'to make it'possible to provide an inexpensive, although practical, building material of this character; and in order to accomplish ythis object, I provide a novel process whereby creases can be formed in plaster 'board vto enable columnar or cellular shapes or blocks fto be formed. Thus a knock down block is.

- terial which is rendered uniformly porous in the making and thus 'capable of absorbing sound. This unit is so constructed and arranged in wall, floor or ceiling structures as to rovide additional air spaces or pocket which further enhance the heat insulating and sound absorbing properties thereof. It is therefore another object of my invention to provide a heat insulating unit which when made a art of the wall, floor, or ceilinfrstructure, will render said structure sound proof and of a character capable of reventing echoes by virtue of the sound absor ing-.qualities of the material comprisingthe unit.

My invention possesses manyfother advantages, and has other objects which may be made more easily apparent from a consideration of few embodiments of my invention. For this purpose I have .shown several forms in the drawings accompanying and forming part of the present specification. I shall now proceed to describe these forms in detail, which illustrate the general principles of my invention but it is to be understood 'that this detailed description is not to vbe taken in a "limiti j sense since Ithe `scope `of im invention is"` st defined l'by the appended claims.

This is a div'isonlof/my prior application Serial No. 377,207, filedJu y 10, 1929.

Refer-ring fto the'drawings:

Figure l vis a diagrammatic plan view of a machine :arranged to vform the novel plaster board;

Figure .2 is avsideelevation thereof;

y Figs. '3 and 4 `are perspective views of two forms of plaster board made in 'accordance with my invention;

Fi 5 is an end view-showinghow plaster boar constructed in accordance with Fig. 3 can be formed into a'fho'llow block.;

Fig. 6 is a view `similar to Fi .5, but showing how 'the plaster yboard of ig. -4 can be used to "formahollow block or conduit;

Fig. 7 isa sectional view/cfa wall,cei`ling, or floor structure utilizing l,my invention;

Fig. `8 `shows .a modied 'form of my invention, utilized in connection with La 'floor structure' Fig. l9 is afperspective 'view `of'a. foldable plaster board that v'is a modification of the form shown in Fig. '3;

Fig. 10 is a lan Yview of the :board shown in Fig. 9 in fo ded position;

Fig. 11 indicates how one variety of the boardcan lbe used 'lto form fa wall `or 'partition in such a lway `as ycompletely to encompass or enclose the supporting :columns vor studding;

Fig. 12 is a view similar to Fig. 7, but showin-g fa slightly modified form :of 'block su 1 ort; andf ig. l13 is a fragmenta y view 'of a further modification ofthe f'old'av Vle board.

The 'apparatus for making' the 1plaster vboard can in general ibe similar to :that disclosed in `my prior application, Serial No.

27 8,537 entitled Wall covering and method of malng same, and filed yon May 17 1928.

The lmachine is shown, therefore, mere y diagrammatically. It rcan be made .so that the board .is manufactured 'first in la continuous length, cut later fon 'intostandard widths and lengths; v.or else the board can be manufactured Vin 1 redetermined sizes. In theorm shown vin rigs. :1f1and12,fthe'process `ofmanuyacturin'g is shown Vas lcarried Lon jto form a plastic filler material can be placed for def' positing it onto the backing 11. ThisI plastic filling, as disclosed in my prior application, can be an effervescent gypsum mixture, to

form cells and voids in the finished filling; or

else there can be added a large percentage of zonolite, pumice, or other porous materials or mixtures thereof.` Optionally, such porosity can be secured by a combination 0f porous particles embedded in effervescing gypsum. I

The material 16 delivered from hopper 15 onto the moving backing material 11 is spread to form a substantially uniform and a relatively thick layer by the aid of the lstationary bars 17 placed transversely above table 14. The upper backing material 12 is fed over a roller 18 and onto the material 17. One or more rolls 19 serve to form the three-layer material to definite thickness.

As thus far described, the apparatus is in no wise materiallydifierent from that disclosed in my prior application. .Before continuing with the description of the apparatus, attention is invited to the form of the product shown in Figs. 3 and 4. In Fig. 3, a plaster boardis shown having a plastic filling 20 and backings 21 and 22. One or more parallel creases, such as 23, 24, 25, are provided, so that the plaster board can be folded on the creases to form a hollow conduit or block, or to facilitate placing the board to form angles at the creases. These creases as indicated in Fig. 3, lcan be made in both the top and bottom, so that the backings 21, 22, nearly touch at or near a point intermediate between the two main surfaces of the board.

In Fig. 4, a form` of board is shown that has but one backing 26. The filling 2*( is. however, creased as indicated at. 28, 29,30, to

permit folding 'at these lines. Filling 20, 27.

can be-solid or porous, as hereinbefore mentioned. The single backing form of Fig. 4 can .be made by leaving off the top backing material 12 while the machineof Figs. 1 and 2 operates.

In the form of .the machinedisclosed, the creases are formed .longitudinally of; the backing materials by the aid of driven creasing rolls31, 32 disposed either on top, or both on top and bottom of thevplaster board as it leaves the rolls 19, and while the filling therein is still plastic. f. Greases 33, 34. 35 can-thus be formed. The creaser shoulders 3.6 on rollers 31, 32 can be arranged thereon in such Ya way as to secure they desired spacing and number of the creases; and it is intended that there be supplied a number of sets of creaser rollers with different spacings and arrange- 4any well understood manner.

"The uses of the creased material are many and varied. For example, hollow conduits can be formed thereof, which can if desired terial. Thus in Fig. 5 I show how the board of Fig. 3 can be folded to form a hollow block, having an overlapping'edge l37. vIn Fig. 6, I show a folded plaster board 39 placed over a column 38 to sheathe it in fire resisting material. Any form of column can be thus covered, by using appropriately proportioned creased boards.

As van example of thev mode in Vwhich the creased board can be utilized to form insulating partitions, attention is called to Fig. '7. In this instance, wood studdings 40 are 'llo . be filled with acoustic or heat insulating mashown, spaced apart uniformly. This is the i usual form of wall ysupports for houses. Between the studdings are placed the rectangular hollow blocks 41, of the general form shown in Fig. 5. The short side 42 can first be nailed to the inner face of a studding, in

lsuch a way that its top edge is fiushiwith the end surface of the studding. Then the opposite side 43 can be correspondingly nailed onto the contiguous studding face, and the long, upper side 44 can be folded over to complete the block, the extending edge 45 covering the edge of the studding, and nailed thereon. The space between the studdings can lthus be completely covered.

Since the top sides 44 of all the blocks thus formed provide a substantially continuous surface, and since the material from which the hollow block is made is non-inflammable, the effect is that a partition of substantially fire proof character is provided. Ordinarily, a single layer of such hollow blocks is sufficient; however, if the depth of studdings 40 permits, another layer of the lblocks can be placed into position on the other side .of the studdings as indicated in Fig. 7. There may be an air space 46 between the block layer. If desired, these spaces 46 as well as the blocks 41 themselves can be filled with heat insulating-or sound deadening material, such as hair felt, pumice, or the like.

The blocks can be used not only for wall partitions, but for many other purposes,` such as ceilings andfioors. In Fig. 8, I show a Hoor structure` utilizing my new material. Upon a supporting member 47 are fastened as by nailing, series of hollow blocks 48, filled if desired with fireprooiing or heat insulating or sound deadening material. this instance are shown as trapezoidal in The blocks in form, and as having extending 4edges 49, whereby grooves such as 50 can be formed between the blocks. Into these grooves and above the blocks can be placed material 51 such as concrete or the like to form the floor surface. The trapezoidal form of the blocks 48 provides a rigid supporting structure for material 51.

It is sometimes unnecessary that all four sides ofthe hollow block he of the same thickness; as for example, in Fig. 7, the external faces of the block only, need to be strong so as to support the finish layers, such assmooth plaster or stucco. In the formvof block illustrated in Figs. 9 and 10, only the top side 52 is heavy, the other sides 53, 54, thin. This eect can obviously be secured by the aid of rollers acting on the material infthe course of manufacture, and while the plastic material is still pliant.

In Fig. 11 I show a scheme whereby the s tudding for a partition can be entirely encompassed by the blocks. In this instance, instead of wood studdings, I show evenly spaced structural iron columns 56. Around each column a block 57 is placed, the block being long enough to lill all the intervening disstance from column to column. The columns are thus located next to a short side of the block, which can be filled in with heat insulating or fire proof or sound absorbing material 58. To hold the blocks to the columns, clips 59, struck up from the columns, can be used. Furthermore, to prevent slipping between the blocks where they abut, a projection 60 can be provided on one side of each bock, tting into a corresponding groove in the contiguous face of the adjacent block. Thus a keying eect is provided.

It is of course understood that as many courses of the blocks shown in Figs. 7, 8 and- 11 are used as necessary to complete the desired partition, wall, ceiling or floor. Thus in effect I provide a knock down building block that is easy to ship, light in weight, and inexpensive to manufacture. It furthermore has highly desirable 'fireproongand sound absorption qualities.

In Fig. 12, the hollow blocks 61 are shown as supported similarly to those of Fig. 7, but there are added the metal rest bars 62 to provide strength, as for a' flooring.

In Fig. 13, I show a creased'board 63 in which the creases 64 in each backing 65 extend substantially as deeply as the thickness of the bf ard, the sides of the opposite creases being in contact. In this way, the bending of the board 63 in either direction is facilitated, the bend being accomplished at either of the two creases.

I claim:

l. A partition structure, comprising a series of spaced supports and a series of hollow blocks made of foldable building material,

encompassing a support and abutting each other.,

2. A partition structure, comprising a series of spaced supports, and a series of hollow blocks, each encompassing a support vand abutting each other, eac'h of said blocks being formed of foldable building material of considerable thickness.

3. A partition structure, comprising a series of spaced supports, and aseries of hollow blocks made of foldable building material each encompassing a support and abutting each other, each block being so formed that a projection on one sidethereof will tit into a corresponding depression in the side of the abutting block and thus provide a keying structure.

4. The process of constructing a partition which includes spacing a series of columnar supports, fastening a side portion of a hollow block blank to one of the faces of a support, said face being spaced and parallel toa corresponding face on an adjacent support, the part of the blank corresponding to the bottom `of the block extending therebetween, fastening the opposite side portion of the blank to said corresponding face, and folding the remaining side of the blank to form a block, and fastening an extending edge thereof over said first named support.

In testimony whereof I have hereunto set my hand.

. J OHN' H. DELANEY. 

